Concrete Innovation Journey in Michigan
Innovation in Concrete
Steve Waalkes, P.E.
Director of Engineering – W. Mich.
Michigan Concrete Association
High Level Overview of Concrete Innovation
•
Competition & communication
are the keys to innovation
•
Always lessons to learn – have
to keep trying, implementing new
ideas
•
Solving problems & making
improvements before they
become problems
2
Long History of Innovation in Michigan
•
1909 – U.S. first full mile of concrete highway, on
Woodward Ave., 6 Mile Rd. to 7 Mile Rd.
•
1911 – U.S. first painted centerline
•
1912 – U.S. first highway materials testing lab
•
1918 – U.S. first 4-way red/yellow/green signal
•
1929 – U.S. first paved runways at Ford Airport in
Dearborn
•
1955 – World’s first freeway-to-freeway interchange
•
1960 – U.S. first state to complete border-to-border
interstate (I-94, Detroit to New Buffalo)
3
Recent History of Concrete Innovation in Michigan
•
Movement towards Performance Related Specifications
•
Midwest Concrete Consortium started (precursor to NC
2
) – state
DOT’s and industry collaboration
•
Increase in state gas tax funding; included are requirements for
pavement warranties and LCCA
•
P1Mod spec first developed by MDOT concrete engineers
•
Re-tooling of the P1Mod spec; requires 3 aggregates, well-graded,
optimized blend
4
Mid-
1990’s
1997
2004
Recent History of Concrete Innovation in Michigan
(cont.)
•
P1Mod upgraded: stockpile management, process control
•
MCA funded study indicates ASR, air entrainment, and other
issues are to blame for some early durability problems
•
I-96 and Ambassador Gateway projects utilize stabilized
subgrades
•
Supplementary cementitious materials required at min. of 25%
•
Optimized mixtures for use in bridge elements
•
FHWA, CP Tech Center, and MDOT start NC
2
PEM implementation
5
2005
2006
2010
2015
Recent History of Concrete Innovation in Michigan
(cont.)
•
MDOT specs allow ASTM C595 Type IL cement
•
MDOT demonstrates 30- and 50-year designs, utilizing stabilized
subgrades (among other improvements)
•
WisDOT adopts optimized/well-graded concrete mixtures
•
New MDOT spec book, P1M now called 3500HP
•
MCA & MDOT discussing innovative concepts including:
•
Stabilized subgrades; Thickened edge for truck lane; Recycling
concrete into 3-inch minus material, into subgrade
6
2015
2018
2020
2021
FHWA Emphasis on Pavement Foundation(s)
7
“…ME designs do not consider the
effects of any deterioration or
spatial variability in the
foundation layers. Over time, the
conditions of the foundation
layers can degrade and deform
under the influence of repeated
heavy loads, leading to non-
uniform support conditions and
localized failures. Thus, the
principal role of a robust
pavement foundation is ensuring
the foundation layers retain their
integrity throughout the
pavement life.”
MDOT Specifications:
•
12SP-604B-11 (Quality Control and Acceptance of Portland Cement Concrete):
•
Required for all trunkline
•
12SP-604B
•
Moving to new spec. book
•
3.09 Optimized Aggregate Gradation
•
MDOT MQAP Manual
Maximum Cement Content and W/C:
•
Maximum Cement Content:
•
Pavements: 564 lbs.(6 sack)
•
Bridge Decks: 611 lbs. (6.5 sack)
•
Maximum W/C Ratio:
•
0.45
•
Benefits:
•
Reduced paste content
•
Reduced costs associated with cement
•
Difficulties:
•
Dependent on Water Reducing Admixtures
•
Local Cement testing
Supplementary Cementitious Materials:
•
Improvements:
•
Permeability
•
Resistance to Freeze-thaw damage
•
Consistency
•
Difficulties:
•
Initial pushback/learning curve
•
Can cause air issues
•
Slower initial strength gains
•
Replacement rates:
•
25%-40% replacement of Portland
cement
•
Replacement amount is determined
by the Contractor
•
40% total replacement
Optimized Aggregates:
•
Improvements:
•
Slump/Consistency
•
Permeability
•
Additional aggregates gradation used
•
Difficulties:
•
Agency and Contractor understanding
•
MDOT Optimized Aggregate Spreadsheet
•
Ready Mix with limited bins
•
Preblended aggregates
•
2 aggregate gradation blends
PEM (Performance Engineered Mixtures)
•
Pooled Fund Study
•
19 state DOT’s
•
4 national industry associations
•
Implement newer technologies to
deliver enhanced concrete
durability & maximize pavement
performance
PEM (Performance Engineered Mixtures)
•
V-Kelly Ball (V-Kelly)
•
Box Test
•
Maturity Method
•
Formation Factor
•
Surface Resistivity
•
Bulk Resistivity
•
Sequential Air Metric Apparatus/Super Air Meter (SAM)
PEM Testing
•
V-Kelly Ball (V-Kelly):
•
Has been used in the lab
•
Have not required its use on
Projects
•
QC Test
PEM Testing
•
Box Test:
•
Has been used in the lab
•
Have not required its use on
Projects
•
Perhaps require its use for trial
batches in the future
•
QC
Test
PEM Testing
•
Maturity Method:
•
MDOT Special Provision
•
Contractor’s option
•
Open to traffic only
•
Training is key:
•
Fingerprints correct
•
Doesn’t measure strength
development – it predicts it
PEM Testing
•
Formation Factor:
•
MDOT has not used the
formation factor
•
Mainly focused on resistivity
testing
PEM Testing
•
Surface Resistivity:
•
Testing was performed on 2 long-life (30 and 50
year) pavement projects
•
Was being conducted on all freeze-thaw samples
•
40+ sets of coarse aggregate samples were tested
•
All testing and mix ingredients were provided to
Jason Weiss at Oregon State University
•
MDOT’s experience:
•
Fairly high level of variability
•
Must hold Probes perpendicular to the surface
•
Ensure the Probes’ reservoirs are full
•
Keep Probes away from voids and aggregate located on
the surface
•
Currently, MDOT has transitioned to Bulk
Resistivity
PEM Testing
•
Bulk Resistivity:
•
Used on multiple research & pilot
projects
•
MDOT’s experience:
•
Simpler test than surface resistivity
•
Consistent results
•
Ensure the sponges remain wet
•
Keep away from metal
•
Correlates with surface resistivity
•
Correlated well with RCP in recent
research project
PEM Testing
•
Bulk Resistivity:
•
Currently MDOT is collecting data
•
Performed on all freeze-thaw
samples
•
Perhaps require its use for trial
batches in the future?
PEM Testing
•
Super Air Meter (SAM):
•
MDOT owns 19 SAMs
•
Introduced to Region personnel
•
Pilot field Testing/Shadow SP:
•
12CF601
•
Requires testing for information only:
•
Mainline Pavement
•
Structures
•
Barrier
•
One test per sublot
•
Typically 5 tests per day for mainline paving
PEM Testing
•
Super Air Meter (SAM):
•
Michigan Concrete Association’s SAM
Certification Class:
•
2 train-the-trainer classes completed
•
3 certification classes completed
•
In-field, on-site training in 2020
PEM Testing
•
Super Air Meter (SAM):
•
Shadow SP: 12CF601
•
Placed in multiple projects:
•
Previous:
•
I-75, Monroe
•
US-131, Grand Rapids
(Rockford)
•
I-69, Flint
•
Information provided to Federal
Highway and CP Tech Center
PEM Testing
•
Super Air Meter (SAM):
•
Shadow SP: 12CF601
•
Project Complete in 2020:
•
I-496, Lansing
•
66 complete samples
•
2021 Research Project:
•
University of Michigan
•
Hardened air analysis of 75
samples
•
Future projects?
Lansing
PEM Testing
•
Super Air Meter (SAM):
•
MDOT’s Experience:
•
Introduce the SAM gauge
•
Inspectors experience
Time to run the test
•
Do not store wet gauges in cases
•
Do not leave the gauges in the air-
conditioned cab prior to testing
•
Always have spare batteries
•
Have a backup gauge
•
Use the Shotgun
•
Follow the gauge’s directions
PEM Testing
•
Super Air Meter (SAM):
•
Future Use:
•
QC?
•
Mix Design Verification?
•
Quality Assurance Daily Test?
•
Random number Testing?
•
PWL?
Summary
•
Michigan has a history of innovation
•
More innovation in the works
•
Not all innovations prove themselves
to be worth it
•
Concrete open and suited to
innovation
•
We have the tools to properly assess
Performance Related Specifications
and new materials to be added to
concrete
27
Special Thanks To:
Ethan Bahmer, MDOT CFS
Bahmert1@Michigan.gov
(517) 230-0190
Explore the fascinating history of concrete innovation in Michigan, from the early milestones in the 1900s to recent advancements like performance specifications, optimized mixtures, and sustainable practices. Discover how collaboration between industry and state entities has led to significant improvements in concrete technology and infrastructure development.
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Presentation Transcript
Innovation in Concrete Steve Waalkes, P.E. Director of Engineering W. Mich. Michigan Concrete Association
High Level Overview of Concrete Innovation Competition & communication are the keys to innovation Always lessons to learn have to keep trying, implementing new ideas Solving problems & making improvements before they become problems 2
Long History of Innovation in Michigan 1909 U.S. first full mile of concrete highway, on Woodward Ave., 6 Mile Rd. to 7 Mile Rd. 1911 U.S. first painted centerline 1912 U.S. first highway materials testing lab 1918 U.S. first 4-way red/yellow/green signal 1929 U.S. first paved runways at Ford Airport in Dearborn 1955 World s first freeway-to-freeway interchange 1960 U.S. first state to complete border-to-border interstate (I-94, Detroit to New Buffalo) 3
Recent History of Concrete Innovation in Michigan Mid- 1990 s 1997 Movement towards Performance Related Specifications Midwest Concrete Consortium started (precursor to NC2) state DOT s and industry collaboration Increase in state gas tax funding; included are requirements for pavement warranties and LCCA P1Mod spec first developed by MDOT concrete engineers Re-tooling of the P1Mod spec; requires 3 aggregates, well-graded, optimized blend 2004 4
Recent History of Concrete Innovation in Michigan (cont.) 2005 2006 P1Mod upgraded: stockpile management, process control MCA funded study indicates ASR, air entrainment, and other issues are to blame for some early durability problems I-96 and Ambassador Gateway projects utilize stabilized subgrades Supplementary cementitious materials required at min. of 25% Optimized mixtures for use in bridge elements FHWA, CP Tech Center, and MDOT start NC2 PEM implementation 2010 2015 5
Recent History of Concrete Innovation in Michigan (cont.) 2015 2018 MDOT specs allow ASTM C595 Type IL cement MDOT demonstrates 30- and 50-year designs, utilizing stabilized subgrades (among other improvements) WisDOT adopts optimized/well-graded concrete mixtures New MDOT spec book, P1M now called 3500HP MCA & MDOT discussing innovative concepts including: Stabilized subgrades; Thickened edge for truck lane; Recycling concrete into 3-inch minus material, into subgrade 2020 2021 6
FHWA Emphasis on Pavement Foundation(s) ME designs do not consider the effects of any deterioration or spatial variability in the foundation layers. Over time, the conditions of the foundation layers can degrade and deform under the influence of repeated heavy loads, leading to non- uniform support conditions and localized failures. Thus, the principal role of a robust pavement foundation is ensuring the foundation layers retain their integrity throughout the pavement life. 7
MDOT Specifications: 12SP-604B-11 (Quality Control and Acceptance of Portland Cement Concrete): Required for all trunkline 12SP-604B Moving to new spec. book 3.09 Optimized Aggregate Gradation MDOT MQAP Manual
Maximum Cement Content and W/C: Maximum Cement Content: Pavements: 564 lbs.(6 sack) Bridge Decks: 611 lbs. (6.5 sack) Maximum W/C Ratio: 0.45 Benefits: Reduced paste content Reduced costs associated with cement Difficulties: Dependent on Water Reducing Admixtures Local Cement testing
Supplementary Cementitious Materials: Replacement rates: 25%-40% replacement of Portland cement Replacement amount is determined by the Contractor 40% total replacement Improvements: Permeability Resistance to Freeze-thaw damage Consistency Difficulties: Initial pushback/learning curve Can cause air issues Slower initial strength gains
Optimized Aggregates: Improvements: Slump/Consistency Permeability Additional aggregates gradation used Difficulties: Agency and Contractor understanding MDOT Optimized Aggregate Spreadsheet Ready Mix with limited bins Preblended aggregates 2 aggregate gradation blends
PEM (Performance Engineered Mixtures) Pooled Fund Study 19 state DOT s 4 national industry associations Implement newer technologies to deliver enhanced concrete durability & maximize pavement performance
PEM (Performance Engineered Mixtures) V-Kelly Ball (V-Kelly) Box Test Maturity Method Formation Factor Surface Resistivity Bulk Resistivity Sequential Air Metric Apparatus/Super Air Meter (SAM)
PEM Testing V-Kelly Ball (V-Kelly): Has been used in the lab Have not required its use on Projects QC Test
PEM Testing Box Test: Has been used in the lab Have not required its use on Projects Perhaps require its use for trial batches in the future QC Test
PEM Testing Maturity Method: MDOT Special Provision Contractor s option Open to traffic only Training is key: Fingerprints correct Doesn t measure strength development it predicts it
PEM Testing Formation Factor: MDOT has not used the formation factor Mainly focused on resistivity testing
PEM Testing Surface Resistivity: Testing was performed on 2 long-life (30 and 50 year) pavement projects Was being conducted on all freeze-thaw samples 40+ sets of coarse aggregate samples were tested All testing and mix ingredients were provided to Jason Weiss at Oregon State University MDOT s experience: Fairly high level of variability Must hold Probes perpendicular to the surface Ensure the Probes reservoirs are full Keep Probes away from voids and aggregate located on the surface Currently, MDOT has transitioned to Bulk Resistivity
PEM Testing Bulk Resistivity: Used on multiple research & pilot projects MDOT s experience: Simpler test than surface resistivity Consistent results Ensure the sponges remain wet Keep away from metal Correlates with surface resistivity Correlated well with RCP in recent research project
PEM Testing Bulk Resistivity: Currently MDOT is collecting data Performed on all freeze-thaw samples Perhaps require its use for trial batches in the future?
PEM Testing Super Air Meter (SAM): MDOT owns 19 SAMs Introduced to Region personnel Pilot field Testing/Shadow SP: 12CF601 Requires testing for information only: Mainline Pavement Structures Barrier One test per sublot Typically 5 tests per day for mainline paving
PEM Testing Super Air Meter (SAM): Michigan Concrete Association s SAM Certification Class: 2 train-the-trainer classes completed 3 certification classes completed In-field, on-site training in 2020
PEM Testing Super Air Meter (SAM): Shadow SP: 12CF601 Placed in multiple projects: Previous: I-75, Monroe US-131, Grand Rapids (Rockford) I-69, Flint Information provided to Federal Highway and CP Tech Center
PEM Testing Super Air Meter (SAM): Shadow SP: 12CF601 Project Complete in 2020: I-496, Lansing 66 complete samples 2021 Research Project: University of Michigan Hardened air analysis of 75 samples Future projects? Lansing
PEM Testing Super Air Meter (SAM): MDOT s Experience: Introduce the SAM gauge Inspectors experience Time to run the test Do not store wet gauges in cases Do not leave the gauges in the air- conditioned cab prior to testing Always have spare batteries Have a backup gauge Use the Shotgun Follow the gauge s directions
PEM Testing Super Air Meter (SAM): Future Use: QC? Mix Design Verification? Quality Assurance Daily Test? Random number Testing? PWL?
Summary Michigan has a history of innovation More innovation in the works Not all innovations prove themselves to be worth it Concrete open and suited to innovation We have the tools to properly assess Performance Related Specifications and new materials to be added to concrete 27
Special Thanks To: Ethan Bahmer, MDOT CFS Bahmert1@Michigan.gov (517) 230-0190
